Danish mobile machining outfit CNC Onsite has extended its in-situ yaw ring repair service, which can now handle a range of common wind turbine platforms.
Since nacelle layouts and working space around the yaw ring differ, each turbine type requires a custom machine setup.
CNC Onsite says the expanded service will allow it to meet the growing demand for cost-effective repair over replacement.
By conducting repairs up-tower, CNC Onsite eliminates the need to disassemble the nacelle using cranes.
This benefits the environment by lowering carbon dioxide emissions and is also safer for technicians, CNC Onsite said.
Sales director and partner Soren Kellenberger said: “The number of turbines nearing the end of their design life is increasing.
“Therefore, even though the percentage of turbines with yaw ring gear issues is relatively low, the total number of turbines that can benefit from this solution is increasing.
“This, and the rising interest in lifetime extension has led us to offer the repairs across more wind turbine platforms.”
To serve the most common wind turbine manufacturers, CNC Onsite has invested in additional engineering resources to develop its up-tower yaw ring repair service.
Two years ago, CNC Onsite established a technical centre in Vejle, Denmark, housing mechanical and electrical development as well as a 2000 square-metre workshop to test and validate its repair methods.
CNC Onsite’s portable machines have been used to install more than 100 new yaw ring segments, equivalent to 600 teeth, on offshore and onshore turbines.
The toothed yaw ring gear keeps the rotor blades aligned with the wind direction for maximum power generation but over time, its teeth can wear down or break (pictured).
Potential causes include sustained loads or unpredictable wind events. Ignoring yaw ring tooth damage not only reduces energy production but also risks wider wear on the rotor blades and drivetrain, potentially leading to costly failures.
CNC Onsite says its yaw repair service costs a fraction of replacing the entire yaw ring, the conventional alternative.
The proprietary machine incises the damaged yaw teeth to extremely fine tolerances, leaving a pocket with dimensions that fit the new replacement segment exactly, the company said.
CNC Onsite will demonstrate the machine at WindEurope in Copenhagen this April.